Method of pile treatment in pile fabric manufacture



Aug. 11, 1970 w. HERKENBERG METHOD OF PILE TREATMENT IN FILE FABRIC MANUFACTURE 2 Sheets-Sheet 1 Original Filed June 19, 1967 FIG.4

G R E mm R E VH me N A G F w W Q MM ATTORNEYS Aug. 11, 1970 w. HERKENBERG METHOD OF FILE TREATMENT IN FILE FABRIC MANUFACTURE 2 Sheets-Sheet 2 Original Filed June 19, 1967 .uwztvprlpzvzv. 1

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M lw huml lm M w "M |r Tm INVENTOR. WOLGANG HERKENBERG y w/ma l m l ll lmgfl iwmumlmminilmliulnmmniun United States Patent Office 3,523,429 Patented Aug. 11, 1970 Int. Cl. D04b 9/14 6 US. Cl. 66-9 9 Claims ABSTRACT OF THE DISCLOSURE In a method of producing pile fabric, typically on a pile circular knitting machine, the pile filaments are treated with a fluid directed transversely of the filaments while they are in exposed condition transversely of the ground fabric, and before they have been covered by a succeeding layer of pile held by the next course of knitting. Usually each carding head of the machine has an air nozzle to blow the pile inward, and this is followed by a needlelike nozzle to deliver the fluid transversely of the pile, and to a desired part only of the length of the pile.

CROSS-REFERENCES TO RELATED APPLICATION This is a division of my application Ser. No. 646,909, filed June 19, 1967 entitled Pile Treating Attachment for Pile Fabricating Machines and now US. Pat. No. 3,461,- 689, granted Aug. 19, 1969.

BACKGROUND OF THE INVENTION Heretofore pile fabrics have been dyed after removal from the machine on which they are formed, usually a knitting machine. Attempts have been made to produce a two-tone effect by tipping or dyeing only the ends of the pile. It has also been attempted to use and blend fibres of different color in the knitting machine. It has also been suggested to use long fibres of one color and short fibres of another in an effort to produce a guard hair effect. However, the desired effect is spoiled by the fact that the color of the long guard hair extends all the way to the bottom. In dyeing a high pile fabric it is diflicult to obtain adequate dye penetration, and in tipping the top part only of the pile, it has been difficult to dye the tips to a uniform depth.

All of the techniques heretofore used have required additional manufacturing steps following removal of the fabric from the forming machine.

SUMMARY OF THE INVENTION In accordance with the present invention the pile is treated in the forming machine preferably by directing a fine stream of fluid directly against the sides of the tufts of pile as the pile is being produced, and while the turfs project transversely from the ground fabric. The invention is here specifically disclosed as embodied in a slivertype knitting machine in which the slivers are inserted into the corresponding portion of the ground fabric substantially promptly after that fabric portion has been knitted, and in such a machine the treatment of the pile preferably occurs at a point following each sliver head and While the pile being treated is fully exposed as the end course is being knit; the invention is, however, applicable for use in connection with other types of pilefabric-forming apparatus such as, by way of example and without limitation, systems in which the pile is introduced into the ground fabric in a form other than slivers, systems in which the pile is secured to the ground fabric in any appropriate manner, and systems in which the ground fabric is fully formed before the pile is attached hereto.

The fluid most commonly used is a dye, but it could be a masking fluid which reduces dye aflinity in order to subsequently prevent acceptance of a dye at the treated parts of the pile. The fluid may be steam or a heated gas applied for the purposes of shrinking desired parts of the pile. The fiuid may be discharged through very fine nozzles or hollow needles, so that it may be directed against a desire part only of the length of the pile. Two collateral hollow needles may be used to apply two different fluids to two different parts of the pile, one nearer the tips, and the other nearer the ground fabric.

The apparatus may further include means to periodically interrupt the flow of fluid, making it possible to produce stripes of treated pile separated by stripes of untreated pile, the timing of the intermittent flow being in synchronized relation to the operation of the knitting machine, so that the stripes are formed in a desired direction. tion.

The treatment may be a chemical treatment for increased lustre, silkiness of hand, or resistance to matting. It may be for water repellancy, or for crush resistance, or increased resistance to wear, or to prevent matting of the pile. For these purposes the entire length of the pile may be treated. The present improvement has the advantage that the pile is fully exposed for treatment as it is being knit, and regardless of whether the pile is a long pile or a short pile.

In accordance with the present invention, the pile fibres are chemically treated or dyed immediately after they have been laid around and bound into the fabric by the knitting needles, and before another line or course of tufts of pile has been added. Because the pile fibres are essentially parallel and fully exposed at this time, it is possible to apply the chemical or dye over the entire length or over any desired part of the full length of the pile fibres.

The foregoing and additional features are described in the following detailed specification, which is accompanied by drawings in which:

FIG. 1 is a plan view schematically representing a circular pile knitting machine with nozzles located between the carding or sliver heads;

FIG. 2 is a perspective view showing a single nozzle;

FIG. 3 is a fragmentary plan view showing a single spray type nozzle using air and liquid;

FIG. 4 is a fragmentary plan view showing how two nozzles may be used to apply different fluids to different parts of the same tufts of pile;

FIG. 5 is a perspective view schematically showing how the supply of fluid may be made intermittent in synchromism with the operation of the knitting machine, in order to produce stripes of treated pile separated by stripes of untreated pile;

FIG. 6 is a fragmentary sectional view showing treatment of the outer ends or tips of the pile;

FIG. 7 shows treatment of the inner or ground portion of the pile;

FIG. 8 shows pile which has been intermittently short ened by heat treatment;

FIG. 9 shows pile which has been treated at two different points along its length;

FIG. 10 shows treatment or coloring of the pile in stripes; and

FIG. 11 shows pile dyed near the ground fabric and later carved to intermittently expose the dyed pile between uncarved portions of the pile.

The figures disclose the invention as embodied in a circular pile knitting machine of the sliver type, but this is by way of exemplification only, and the invention is applicable for use in other and different types of apparatus.

Referring to the drawing and more particularly to FIG. 1, a circular pile knitting machine is schematically shown in plan view, it having a circular bed plate 12 with a plurality of carding or sliver feeding heads 14 distributed therearound. It has a rotary knitting cylinder 16 with needles, with no attempt here to show the needles or other details. As usual, a knitting needle picks a tuft of slivers or pile fibre just before knitting a loop, and thus the tuft is locked into the loop. There is an air blower nozzle 18 immediately following each of the sliver feeding heads to position the pile radially inward of the tubular knit ground fabric. The circular pile knitting machine may be conventional, and therefore no further description of the machine mechanism is needed. It will be understood that the tubular knit fabric later is slit open to provide a flat fabric.

In accordance with the present invention a fluid applicator generally designated 20, is mounted on the circular plate 12 between the sliver heads 14. The applicator comprises an adjustable holder carrying a fine nozzle which is essentially a hollow needle 22 supplied with fluid through a slender hose 24. The position of the needle is selected to apply the fluid to a desired part of the pile projecting inward of cylinder 16.

These parts are shown in somewhat greater detail in FIG. 2, in which the base 26 of the applicator is secured to circular plate 12, and has a clamp 28 carrying a rod 30 the position of which may be locked by thumb screw 32. Rod 30 carries a holder 34 for a hollow needle 22, this being supplied through a slender hose 24, the flow through which may be controlled by means of pressure plate 36 the position of which is adjusted by means of a thumb screw 38.

The details of the applicator may be varied greatly, and FIG. 2 is merely one example of such an applicator. The hollow needle 22 is disposed over the inwardly projecting pile 40 of the fabric. The tufts of pile are fully exposed at this time because they are the top or endmost course of the fabric as it is being knit.

Referring now to FIG. 6, I there show a knit ground fabric 42 having pile 44, the ends or tips of which have been dyed as indicated at 46. This may be compared with FIG. 7 in which ground fabric 48 has pile 50 the inner part of which has been dyed to a darker color as shown at 52. It will be understood that to produce the fabric of FIG. 7, the needle is located outward or nearer the knitting cylinder, where as for the fabric of FIG. 6, the needle is located further inward or away from the knitting cylinder. This adjustment is readily accomplished by moving the rod 30 (FIG. 2) relative to the split clamp 28.

In a typical case in FIG. 7 an original undyed grey pile may be dyed brown for most of its length from the ground fabric to a point approaching but not quite reaching the tips, and the result is an artificial fur of good appearance because of the surface haze. In other cases, not seeking to imitate fur, the dye may be a color such as red or blue. All these have an improved appearance because of the light haze effect produced by the grey tips 50 blended into the background color.

Referring now to FIG. 4, in this case two applicators generally designated 54 and 56 are mounted on the circular bed plate 12. Each applicator terminates in a hollow needle indicated at 58 and 60. In FIG. 4 it is assumed that the fluid supply from hoses 62 and 64 is fed through tubular rods 66 and 68, these being radially adjustable in clamps 70 and 72. The nozzle 58 is shown applying one fluid to the pile 74 at a point nearer the ground fabric, while the nozzle 60 is applying a different fluid to the pile at a point nearer the ends of the pile. Thus two different colors may be used, and by appropriate adjustment of the amount of fluid the colors may reach and blend, or may be left somewhat separated if desired. Moreover, the original grey color of the undyed fabric may be left exposed at the tips, while the two dyes coat the remainder of the pile, thus producing a three-tone effect.

FIG. 9 shows a knit ground fabric 76 with pile 74 treated by one nozzle at 76, and by another nozzle at 78.

What is shown in FIG. 9 and FIG. 4 is an extreme case using the fluid at small width on a long pile, but it will be understood that in practice the bands of fluid may be made and usually would be made wider than is shown in FIG. 9.

When it is desired to apply fluid widely, for example to coat the entire length of a long pile, the nozzle may be of the atomizing type using air to produce a spray effect. Such an arrangement is shown in FIG. 3, in which applicator 80 is mounted on circular bed plate 12 between sliver heads. The nozzle 82 has a broadened or fan shaped tip, and is supplied with air through a hose 84, and with dye or other treatment liquid through a hose 86. The air supplied at 84 is in addition to the air nozzles shown at 18 in- FIGS. 1 and 2 to blow the pile inward. The air supplied at 84 is a supply of air directed transversely of the pile" to atomize a liquid in order to deliver the liquid in the form of a spray, compared to liquid delivered through a hollow needle as in FIG. 2. The nozzle 82 is readily adjustable in a clamp 88. With this arrangement it is readily possible to spray the entire length of even a relatively long pile.

Alternatively the double nozzle arrangement of FIG. 4 may be used, with both nozzles receiving the same dye, and with the flow and nozzles adjusted to coat the full length or as much of the length of the pile as desired.

The treatment fluid may be supplied intermittently instead of continuously, and by timing the intermittent flow in synchronism with the operation of the knitting machine, stripes may be produced in a desired direction, typically vertically when using a circular knitting machine as here shown. FIG. 10 shows a ground fabric with a pile 106 which is dyed intermittently at 108, thus forming a striped pile fabric. Mechanism for this purpose is schematically shown in FIG. 5, in which the treatment liquid or dye is supplied from a reservoir 110, preferably through a strainer 112, to a needle valve 114 for accurate adjustment of the rate of flow by means of its control knob 116. The liquid reaches a manifold or distributor 118, where it is divided to flow through as many hoses as there are applicators. In this case there are four such hoses going to four nozzles, as previously described in connection with FIG. 1. The knitting cylinder is schematically' represented at 122, and is rotated by gearing 123 which may be of conventional character.

As so far described the dye would be applied continuously. For intermittent application of the dye a solenoid valve 124 is introduced ahead of the manifold 118. This valve should be of a quick operating type which preferably operates in a fraction of a second and preferably is provided with Teflon inner parts. The supply tubes 20 are small in diameter, so that the flow stops at the nozzles without bleeding or leakage when the valve is closed.

The valve 124 is operated from an electrical supply source which is connected at 126, and which is under the control of a microswitch 128. The switch is operated by camming projections distributed around the knitting cylinder 122. The width and spacing of the stripes is determined by the peripheral length and spacing of the camming projections 130, and the resulting stripes are maintained vertical despite the rotation of the knitting cylinder 122, because the timing of the valve operation is determined by the knitting cylinder itself.

When the liquid feed is gravitational as shown in FIG. 5, it is desirable to supply the reservoir 110 from another reservoir, with appropriate means to maintain a constant level in the reservoir 110, so that the rate of gravitational flow will be maintained constant. Alternatively, the reservoir may be closed and a slight but constant air or gas pressure may be maintained in the reservoir.

The treatment of the pile is not limited to the application of a dye or chemical. Certain synthetic fibres may be greatly shrunk by the application of steam or hot air, and referring to FIG. 8 a ground fabric 100 has a long pile indicated at 102. By supplying steam through the nozzles intermittently, the pile may be intermittently shrunk in stripes, as is indicated at 104. A valve control mechanism like that used in FIG. 5 may be used to control the steam or a heated gas. Here too the control is synchronized with the rotation of the knitting cylinder. Instead of applying steam or heated gas, a specifically different but generically similar treatment medium such as radiant heat could be used.

Some of the above described treatments may be supplemented by later steps to produce even more varied effects. For example, after removal from the knitting machine and slitting of the fabric, the pile may be carved over desired areas to shorten the pile. In FIG. 11 the ground fabric 90 has a pile 92 which is carved or shortened as indicated at 94. This is done after dyeing the inner portion of the pile in the knitting machine as indicated at 96. while leaving the end portions grey or of different color. The carving exposes the inner color in those areas where the pile is shortened. The carving may follow a desired pattern, produced by means already known.

In prior practice for the dyeing of pile knit fabric, the grey material, after removal from the knitting machine and after being slit open, might be treated by means of a long wet roll, or by spraying the pile, but such methods limit the application to the upper part of the pile, it be ing difficult to secure penetration for the entire length of the pile. High pile fabrics would require very special handling because of the limited penetration.

Here too the fluid might be applied through applicators each having a soaked wick, or a porous plate, or a rotating brush, to which the fluid is supplied. The entire length of the pile would be exposed to treatment. However, because the pile is unsupported and delicate, it is found that a nozzle or spray applicator as here illustrated is preferable.

The improvement is not limited to fabrics used for outer clothing, but may be applied to fabrics used for other purposes, for example, decorator throw rugs, carpets, wall coverings, lining materials, and so on.

The chemical used may be one seeking to improve the lustre, or to improve water repellancy, or to prevent matting, or to increase crush resistance, or to increase wear properties. If the liquid or dye being used is not fastdrying, the apparatus may further include infrared lamps or other such heaters disposed over the pile immediately following the applicator or nozzle in the knitting machine.

It is believed that the construction and operation of my improved apparatus for the treatment of a pile fabric directly in the forming machine itself, as Well as the advantages thereof, will be apparent from the foregoing detailed description. It will also be apparent that while I have shown and described the invention in several preferred forms and specifically in connection with a circular pile knitting machine, changes may be made both in the details of the pile tratment and type of pile fabric forming machine With which it is associated.

I claim:

1. In the manufacture of pile fabric including the fabrication of a ground fabric from base yarn and binding of pile fiber into the ground fabric to extend transversely therefrom, the improvement comprising treating selected areas of the projecting pile fiber to alter the characteristics thereof by a fluid medium directed thereagainst in a direction transverse to the length thereof after incorporation into the ground fabric and while still exposed and before a formation of additional ground fabric and additional pile.

2. The method of claim 1, in which the fabrication and binding is effected by knitting, and in which said treatment medium is a liquid.

3. The method of claim 2, wherein the knitting is circular knitting, and wherein a small stream of the liquid is directed against the pile while the pile projects transversely from the ground fabric and is still exposed as the end course being knit.

4. A method as defined in claim 2, in which the liquid applied to the pile is a dye.

5. A method as defined in claim 2, in which the liquid applied to the pile is a silicone liquid for the purpose of preventing matting of the pile.

6. A method as defined in claim 2, which includes directing the liquid in a fine stream as to treat only a desired part of the length of the pile.

7. A method as defined in claim 2, in which the flow of liquid is periodically interrupted and is thereby made intermittent in order to produce sections of treated pile separated by sections of untreated pile, and in which the timing of the intermittent flow is synchronized in relation to the knitting so that stripes are formed in a desired direction on the body of the fabric.

8. A method as defined in claim 1, which includes directing two fluids respectively in fine streams against two different parts of the pile, the part receiving one fluid being nearer the ground fabric, and the part receiving the other fluid being nearer the tips of the pile.

9. A method as defined in claim 1, in which includes repeatedly interrupting the flow of fluid, and timing the interruptions relative to the fabrication and binding as to produce stripes of treated pile separated by stripes of untreated pile.

References Cited UNITED STATES PATENTS 1,767,762 6/1930 Jennings 66147 2,388,648 11/1945 Sheppard 661 2,421,638 6/1947 Moody et a]. 661 2,953,912 9/1960 Hill 66-9 3,295,337 1/1967 Beucus et al 66-9 FOREIGN PATENTS 11,300 1846 Great Britain.

ROBERT R. MACKEY, Primary Examiner 

